Partition structure



Augp?, 1945.-' v BAKER 2,331,635

; VPARTITION STRUCTURE Filed vJune 15, 1942 3 Sheets-Sheet 2 v NelsNelson Serial l Patented Aug. 7, 1945 PARTITION STRUCTURE George W.Baker, Chicago Heights,

to United States Gypsum Company,

Ill., assignor Chicago,

Ill., a corporation of Illinois f Application June 15, 1942, Serial No.447,037

(Cl. 'l2- 46) 13 Claims.

This invention relates to partitions, and more particularly to studs andassociated elements for supporting the plaster base of a substantiallymonolithic or so-called solid partition, that is, partitions having nosubstantial air space within the wall itself. These partitions areordinarily about two inches thick, and it has been common practice tobuild up a plaster base comprising a single layer of gypsum boards orthe like, either perforated or unperforated.

The gypsum boards are ordinarily secured to narrow studs, all of theboards being in the same plane and having their adjacent edges retainedin alignment by means of suitable clips. A comparatively thick layer ofplaster is applied to each side of the plaster base, with which it formsa very rigid bond. When perforated plasterboard is used, the twooppositely disposed plaster layers are further bonded together andbonded to the gypsum board by plaster keys which extend completelythrough the perforations.

In the usual partitions of the above noted rigid type, there is adecided tendency for cracks to form in the plaster coatings after thepartition has been erected for a short time. These cracks may occur atany location on the partition, although they are more apt to appearadjacent the joints between the various pieces of gypsum v boards. Also,when perforated board is used, so-

called Sunburst cracks appear adjacent the various perforations. It hasbeen found that, if the two oppositely disposed plaster layers are notrigidly bonded together, but instead are loosely or yieldably bonded orsupported so that each side of the partition is capable of slight planarmovement or self-adjustment relative to the other, any tendency of theplaster to crack at the board joints or adjacent the perforations or vatany other point is substantially completely eliminated. This latter typeof self adjusting or non-rigid partition is disclosed and claimed in thecopending application of G. W. Baker and No. 447,036, filed June 15,1942, and the instant invention is directed to a partition structure andstud therefor, which structure is particularly adapted for use inpracticing the invention disclosed in the said copending application.

It is an object of the present invention to provide a. substantiallymonolithic or so-called solid partition formed of gypsum boards or thelike and plaster coverings in which the plaster coverings will remainsubstantially free from cracks of any type for a greatly extended periodunder all normal conditions.

It is also an object to provide a solid partition of the type disclosedin which the plaster base comprises a double or multiple thickness ofplasterboard or the like so supported as to enable slight relativeplanar movement therebetween and in which the oppositely disposedplaster coverings may be independently bonded to the relatively movableplasterboards.

A further object is the provision of a particular type plaster basecomprising gypsum boards or the like in which the adjacent edges of theboards are supported in the studding in shiplapped relationship.

Another object of the invention is to provide a substantially monolithicor so-called solid partition and stud therefor of the characterdescribed which will be cheap to manufacture, easy to install, and whichwill be characterized by freedom from plaster cracks. I

Further objects will be apparent from the specification and the appendedclaims.

In the drawings:

Fig. l is a side elevation of one embodiment of the invention before theplaster coverings have been applied and with the oor and ceilingindicated in section.

Fig. 2 is an enlarged detail sectional view taken on a linesubstantially corresponding to line 2-2 of Fig. 1.

Fig. 3 is a transverse sectional elevation taken on a line substantiallycorresponding to line 3-3 of Fig. l.

Fig-4 is a fragmentary sectional perspective view of a portion of theassembled plaster base including a stud and floor and ceiling runners.

Fig. 5 is a perspective view of the upper end of the S-studs shown inFigs. 1 to 4.

Fig. 6 is a perspective view of a slightly different embodiment of studfor supporting the gypsum boards.

Fig. 7 is a detail sectional view taken on a line substantiallycorresponding to line 1-1 of Fig. 6.

Fig. 8 is a transverse sectional view through a slightly different,embodiment in which only one layer of gypsum board is used to form theplaster base and the plaster coverings are loosely bonded to one sidethereof.

Referring to the drawings in detail, the embodiment illustrated in Figs.1 to 5, inclusive, comprises a floor runner I and a ceiling runner 2secured to the oor and ceiling 3 and 4, respec-l tively, as shown inFigs. 1 and 3.

These runners are `preferably of more or less resilient sheet metalsubstantially U-shaped in of S-shaped stud adapted to support a crosssection, with a flat web and outstanding flanges as shown. The edges 5of the flanges are outturned slightly, as illustrated in Fig. 3, toenable easy insertion of the studs and panels therebetween. The runnersmay be secured to the floor and ceiling by means of stub nails 6 driventhrough suitable holes in the web. The ceiling runner 2 is provided onone side with a comparatively narrow flange 1, the opposite ilange 8being materially wider for a purpose which will be described later. Thepartitions are usually erected on the job by positioning suitable studs9 between the lloor and ceiling runners and supporting suitable gypsumboards or the like I0 between these studs to provide a two-ply plasterbase.

The studs 9 are substantially S-shaped in cross section and comprise acentral web III and oppositely disposed anges II which are so relatedthat the edges of gypsum boards I2 may be inserted between the web andeach oppositely disposed flange so that the boards are in overlappingrelation in the stud and the edges thereof are embraced snugly lbetweenthe web and the respective nanges in the manner illustrated in Fig. 2.

The plaster base is preferably a two-ply gypsum board structure, asshown, and the boards may be yieldably secured together by means ofsmall staples I2a or the like, whereby the boards are capable of slightrelative planar movement. The staples illustrated are not essential, butinstead it is contemplated to use small nails or wires or any othersuitable means for securing the boards nonrigidly together so that theremay be some slight self-adjusting movement therebetween. The boards areoifset relative to each other in the manner illustrated so that theyprovide a substantially shiplap joint within the confines of a stud, oneof the boards entering the stud to be embraced between the web and ailange and the other board terminating adjacent the side of the stud.

Thick plaster coverings I3 and I4 are applied to the respective sides ofthe partition, and these coverings form a substantially rigid bond withthe adjacent boards. Each plaster covering, together with the layer ofboard to which it is bonded, is slightly movable or self-adjustablerelative to the other plaster covering and its support, and, therefore,stresses and strains are not transmitted from one side of the partitionto the other with suflicient force to cause plaster cracks.

The outer edges of the stud flanges I I are preferably curved or rolledoutward slightly, as shown at I5, to permit the edges of the gypsumboards to easily be entered into the stud, and these outturned portionspreferably terminate short of the upper end of the stud as shown. Thisenables the upper end of the stud to be easily inserted in the ceilingrunner 2 and to be retained in alignment therein. The stud preferablyterminates short of the floor runner I and the upper end of the stud isretained in the resilient ceiling runner by friction of the runnerflanges against the sides of the stud.

The flange 8 of the ceiling runner 2 is somewhat wider than the oppositeflange I so that the end of the stud may rest against this dependingflange While the Stud is being inserted into the runner. This dependingflange is also of assistance in directing the upper edges of the gypsumboards into the runner. The upper edge of a board panel may be restedagainst the depending flange 8 and the panel raised upwardly into therunner and then seated into the lloor runner and moved laterally intoengagement with a stud. The narrow flange of the ceiling runner ismaterially wider than the corresponding flange of the oor runner so thatthe boards are retained in the runners. The boards, when assembled, aresupported in the floor runner as shown in Figs. 1 and 3, with theiredges engaged in the stud, as shown in Fig. 2.

The studs may be of any desired length, but preferably terminate shortof at least one of the runners, as shown in Fig. 3. If desired, they maybe of sufficient length to extend into both runners. The runners arepreferably of the type shown; however, the studs may be supported in anysuitable manner between the oor and ceiling. Also, if desired, theboards only may extend into the runners to support the partition, andthe S-shaped stud members may then function merely as elongated clipsfor aligning the edges of the boards in shiplap relationship therein.

The S-shaped type of stud disclosed herein presents many advantages inthat it may easily and cheaply be formed merely by rolling elongatedstrips of thin sheet metal, which metal may be of sufficient resilienceto retain the edges of the boards snugly therein.

The plasterboards or the like are preferably of ceiling height to formcomparatively large panels, and they may be of either ordinaryimperforate plasterboard or of the usual perforated type to provide amore eflicient plaster bond. In the embodiment shown the plaster basepanels are of ceiling height. However, the invention also contemplatesthe use of smaller size plasterboard or the like which may be supportedin the studding in the same manner as illustrated and described hereinand, if desired, any adjacent free edges of the plasterboards may besecured together nr retained in alignment by means of clips appliedthereto in the usual well known manner.

Fig. 4 illustrates the use of perforated plasterboard as assembled toform a plaster base. In this embodiment the lboards I0a are providedwith perforations I6, which perforations are usually in longitudinal andtransverse rows. It; will, therefore, be apparent that, when the twolayers of boards are assembled in the staggered relationship shown, theperforations in the respective boards will be out of alignment and,therefore, the two oppositely disposed plaster coverings will not bekeyed together. If desired, and also in the event that the perforationscoincide, the perforations may be coated with a suitable lacquer orother plaster non-bonding agent so that there is no rigid bonding of theplaster therein.

Figs. 6 and 7 illustrate a slightly different embodiment of studconstruction for retaining the two-ply plaster base in assembledrelation without the necessity for using staples, nails, or other meansfor securing the boards together. -In this embodiment, the stud 9a maybe of substantially the same general construction as the stud 9previously described, with the exception that tongues or so-calledknockouts I1 are punched outwardly from the material of the stud andextend substantially parallel with, but in the reverse direction from,the flanges I I so that the tongues overlap the edges of the boards I 2bto retain these boards in assembled relation without using staples,nails, or the like, as previously described.

A slightly different embodiment is illustrated in Fig. 8, in which asingle layer of plasterboard may be used to form a plaster base. In thisembodiment, the edges' of the boards I2 are inserted in overlappingrelation in the stud 9, as illustrated, and each board is provided on atleast one side with a coating I8 to provide a comparatively weak bondingsurface. This coating may be of any suitable type, such as sodiumsilicate, asphalt, or other suitable material, whereby a substantiallyyieldable bond is provided in such a manner as to enable slight relativeplanar movement of the plaster coverings I9 and ZIJ.

It will be apparent that, in the embodiments herein illustrated anddescribed, or their equivalents, a substantially monolithic or so-calledsolid partition may be provided, in which partition there is suiiicientyieldability throughout the assembly to permit relative self-adjustmentof the opposed plaster coverings and to thereby prevent cracking ofthese coverings irrespective of whether imperforate or perforatedplaster base panels are used in the construction.

Fig. 9 illustrates a method of securing a door frame or the like to oneof the studs. In this construction, a sheet metal door buck is shown andmay be secured to the stud by means of a wire 2I inserted through thedoor buck in the manner illustrated and tied around the partition asshown. The wire may extend through a small hole in the edge of one ofthe overlapping panels.

Fig. 10 illustrates the manner of securing the cut edges of theplasterboard base to `a door buck. In this embodiment a strip of floorrunner Ia is placed over the edges of the plasterboard panel and securedto the door buck by means of a wire 22 which is passed through the doorbuck and through the boards forming the panel and tied in the mannerillustrated.

It is intended, of course, that the invention should not be limited tothe specific embodiment or embodiments disclosed herein, sincemodifications may be made, and it is contemplated, therefore, by theappended claims to cover any such modifications as fall within the truespirit and scope of this invention.

Having thus described this invention, what is claimed and desired to besecured by Letters Patent is:

1. A solid partition comprising a plaster base formed of two relativelymovable layers of wallboard in face-to-face relation and laterallyoffset suiiiciently to provide oppositely disposed shiplal edges,S-shaped studs embracing said shiplap edges to support said boardstherebetween in twoply self-adjusting planar relationship, and a layerof plaster on each side of said plaster base.

2. A solid partition comprising a plaster base formed of two relativelymovable layers of wallboard in face-to-face relation and laterallyoffset suiciently to provide oppositely disposed shiplap edges, S-shapedstuds embracing said shiplap edges to support said boards therebetweenin twoply self-adjusting planar relationship, a layer of plaster on eachside of said plaster base, larid floor and ceiling channels forsupporting the top and/'bottoinedges of said plaster' base therein.

3. In a solid partition structure, the combination with a U-shaped iioorrunner and a resilient U-shaped ceiling runner, of a stud substantiallyS-shaped in cross section and frictionally supported in said ceilingrunner, and plasterboards having their edges embraced in overlappingrelation in said stud and with their lower edges supported in said floorrunner.

4. A solid partition structure comprising an elongated studsubstantially S-shaped in 'cross section, a plurality of plasterboardsdisposed `with adjacent boards on opposite sides of a median plane andhaving the adjacent edge of each board embraced between the web and aflange of said stud so that said edges are in overlapping relation insaid stud, said boards and stud forming a plaster base, a layer ofplaster on each side of said base to provide a solid partition, and acoating of bond-weakening material on at least one side of each boardsaid coating comprising bonding means between face-to-face contiguousboards.

5. A solid partition comprising spaced studs of thin sheet metal, saidstuds being substantially S-shaped in cross section so that the spacebetween the web and a ange of a stud is substantially the width of theusual plasterboard, a pair of plasterboards each having an edge engagedin one of said studding between the web and a flange, furtherindependent plasterboards overlapping sad plasterboards throughoutsubstantially the remainder Aof their length, means to retain saidboards in snug face-to-face relationship to form a panel, said retainingmeans enabling relative planar self-adjustment of said boards, and acomparatively thick plaster covering rigidly bonded to each board ofsaid panel.

6. A solid partition comprising spaced studs of thin sheet metal, saidstuds being substantially S-shaped in cross section so that the spacebetween the web and a flange of a stud is substantially the width of theusual plasterboard, a pair of plasterboards each having an edge engagedin one of said studdng between the web and a flange, further independentplasterboards over'I lapping said plasterboards throughout substantiallythe remainder of their length, means to retain said boards in snugface-to-face relationship to form a panel, said retaining meanscomprising tongues struck out of said studs in a position to overlap theadjacent free end of a plasterboard to enable relative planar movementof said boards, and a comparatively thick plaster covering rigidlybonded to each board of said panel.

'7. A substantially monolithic partition comprising sh\ee/t rnetalU-shaped iloormand,ceilllir run ners, sa1d"runners"havirg substantiallyflat webs and outstanding flanges, said ceiling runner having one flangematerially longer than the other with the edges of said flanges rolledor turned outwardly to enable easy insertion of a stud therebetween,studs having their upper ends frictionally embraced by said ceilingrunner and terminating short of said floor runner, said studs beingformed of sheet metal and being S-shaped in cross section so that theflanges of each stud are parallel with' each other and with adjacentrunner ilianges, twoply plasterboard panels supported in said runnersand having overlapping shiplap vertical edges supported in opposite'sides of said studs in overlapping relationship, means to retain saidtwo plies in snug face-to-face relationship while permitting relativeself-adjusting planar movement, and a plaster covering bonded to eachside of said panels.

8. In a panel support for a partition, a. pair of U-shaped sheet metalrunners secured to a floor and-ceiling, respectively, said runnershaving siibstantially'at webs and outstanding flanges, a resilient sheetmetal stud substantially S-shaped in cross section to snugly embrace theedges of oppositely extending plasterboard panels in overlappingrelation, said stud having one end frictionally engaged between theflanges of oneI runner, the opposite end terminating short of the otherrunner.

9. A gypsum boar-d plaster base comprising U- shaped runner channelssecu1;ed to aflQ0aff,1d ceiling, respectively, vertical gypsum boardssup`" ported Yin said oor channel and between the flanges of saidceiling channel and terminating short of the web thereof a distancegreater than th'e height of at least one flange of said oor channel sothat the upper edge of a board may angularly be inserted in said ceilingchannel and the lower edge then inserted and supported in said lowerchannel, said boards having their vertical edges in overlappingrelation, and an elongated thin sheet metal connector conforming to theoverlapping edge contour of said boards and embracing said edges betweena central web and oppositely extending flanges.

10. A partition comprising a stud including a thin sheet-like web insubstantially the central plane of said partition, a plurali-ty ofplasterboards disposed with adjacent plasterboards on opposite sides ofsaid web and each' having an edge portion overlapping said web so thatsaid web is between said overlappingboard edges, and means integral withsaid web for retaining said boards and web in assembled relation.

11. A partition comprising spaced studs, each stud comprising a thin webin substantially the central plane of said partition, relatively movableplasterboards mounted in snug face to face multiply relation betweenpairs of said spaced studs to form multi-ply plasterboard sections, theedges of plasterboard in adjacent sections overlapping a stud web sothat said web is snugly enclosed between plasterboard edges, and meansintegral with said web for retaining said boards and web in assembledrelation.

12. A partition comprising spaced studs, each stud comprising a thin webin substantially the mounted in snug face t0 face multi-ply relationbetween pairs of said spaced studs to form multiply plasterboardsections, the edges of plasterboard in adjacent sections overlapping astud web so that said web/A is snugly enclosed between plasterboardedges, means to secure said plasterboard together to retain all of thesaid elements in snugly 4assembled relation while permitting relativeself-adjusting planar movement between said face to face plasterboardand between said plasterboard and said webs, and a layer of plaster oneach' side of said partitionl 13. An elongated stud for plasterboardpanels in a solid partition of the character described comprising anelongated sheet metal strip formed substantially S-shape in crosssection with the web and anges substantially parallel providingoppositely -directed parallel grooves with the web as a common walltherebetween, said web and anges being spaced to embrace the edges ofoppositely disposed plasterboards1 and resiliently hold them inoverlapping relation to form a plaster base, and tongues struck out fromthe stud flanges, said tongues extending parallel with and in theopposite direction from said iianges to embrace the edge portions offurther plasterboards disposed in substantially the same planes butextending in opposite directions to the iirst mentioned plasterboards.

GEORGE W. BAKER.

CERTIFICATE 0E CORRECTION.

Patent No. 2,581,655. August 7, 1915.

GEORGE w. BAKER;

It is hereby certified. that error appears in the printed specificationof the above numbered patent requiring correction as follows Page b.,seoond column, line 1., claim 12, after the Words "substantially the"insert central plane of said partition, plasterboards; and that the saidLetters Patent should be read with this correction therein that the samemay conform to the record of the oase in the Patent Office.

Signed and sealed this 20th day of November, A. D. l9li5.

Leslie Frazer' (Seal) First Assistant Commissioner of Patents.

